Spring/Summer project…

Using two 8″ subs with a Pyle 1200w amp. (JCWhitney special)



6/6/10 – Got the seat removed tonight and discovered that the frame is a bit different than that shown in the forum where I got the idea from. Not too much, but enough that the box requires a redesign. Completely. The idea remains the same, but the box may actually be a little simpler than the example.

6/9/10 – Started construction. Went fairly well. Got most of the parts cut. Had to custom cut a few pieces. Will take measurements and update the CAD layout dimensions before posting the plans.

6/12/10 – Finished! Installed and working. Sounds GREAT! I estimate approximately 8-10 hours of labor total. Haven’t updated or posted plans yet.

Materials
(1) 3/4″ MDF 4”x8′ sheet. (1/2 sheet will suffice if you can find it pre-cut)
(1) box 1 5/8″ drywall/wood screws
(1) 3/4″ metal angle (36″ is more than enough)
(1) tube Liquid Nails Adhesive (wood glue will work, but Liquid Nails will be better for holding and sealing)

Tools
Metal grinder/cutter
Table Saw
Sabre Saw (Band saw would also be handy)
Drill (w/philips driver and counter-sink bit)
Caulk gun (for tube of Liquid Nails)
Pencil
Utility knife or electric knife – or both
Soldering iron (recommended)
Wood Clamps or C-Clamps

This link is to a forum that shows a 10″ sub installed in a rear seat. This is where my plans originate from. Again, while the idea remains the same, the design and dimensions have changed: www.jeepz.com

Another link shows plans and dimensions for a box made for a 97-02: www.sirgcal.com

Plans with dimensions. Some dimensions will need to be tweaked in construction.

Here are pics of my project. Click on a photo below to enlarge.

Jeep-Subwoofer
Original (temporary) setup
Original (temporary) setup
Original (temporary) setup
Original (temporary) setup
Original (temporary) setup
Original (temporary) setup
Bottom after seat-cover removed. Upholstery easily zips off.
Bottom after seat-cover removed. Upholstery easily zips off.
Remove cross bars.  I used an electric cutting tool (grinder) for ease.
Remove cross bars. I used an electric cutting tool (grinder) for ease.
Cross bars removed.  I painted over the bare metal with satin black to prevent rusting.
Cross bars removed. I painted over the bare metal with satin black to prevent rusting.
Again with cross bars removed.
Again with cross bars removed.
Pieces cut per plans. Assembly begins. Several pieces were measured and cut as I went along for tight fit.
Pieces cut per plans. Assembly begins. Several pieces were measured and cut as I went along for tight fit.
Pieces cut per plans. Assembly begins. Several pieces were measured and cut as I went along for tight fit.
Pieces cut per plans. Assembly begins. Several pieces were measured and cut as I went along for tight fit.
Pieces cut per plans. Assembly begins. Several pieces were measured and cut as I went along for tight fit.
Pieces cut per plans. Assembly begins. Several pieces were measured and cut as I went along for tight fit.
Liquid Nails was used.  Regular wood glue would have probably sufficed.
Liquid Nails was used. Regular wood glue would have probably sufficed.
Since I bought the Liquid Nails, I went ahead and used it instead of the wood glue.  Plenty of wood screws held it all together.
Since I bought the Liquid Nails, I went ahead and used it instead of the wood glue. Plenty of wood screws held it all together.
Screws went in pre-drilled, countersunk holes.
Screws went in pre-drilled, countersunk holes.
Some pieces were cut on a band saw.  It made several small cuts quick and easy.
Some pieces were cut on a band saw. It made several small cuts quick and easy.
One of the "measure and cut as you go" pieces.  Piece is included in plans, but much better to actually measure it as you go for a better fit.
One of the "measure and cut as you go" pieces. Piece is included in plans, but much better to actually measure it as you go for a better fit.
Getting close to all together.
Getting close to all together.
Some MDF split when I screwed it together, even after I pre-drilled it.  I used wood glue and clamped the split pieces together until dry.
Some MDF split when I screwed it together, even after I pre-drilled it. I used wood glue and clamped the split pieces together until dry.
Inside view of the corners.
Inside view of the corners.
Clamps were used to hold pieces tightly together during assembly.
Clamps were used to hold pieces tightly together during assembly.
Inside view of center braces.
Inside view of center braces.
Front corner view.
Front corner view.
Inside front corner view.
Inside front corner view.
One of many test fits.
One of many test fits.
You can never have enough test fits.
You can never have enough test fits.
I added a groove, or a cut-out for a better fit.
I added a groove, or a cut-out for a better fit.
This groove is where the hinge bracket attaches on the frame. Not necessary, but just for a better fit.
This groove is where the hinge bracket attaches on the frame. Not necessary, but just for a better fit.
Cut some 3/4" angle to length and drill some holes.
Cut some 3/4" angle to length and drill some holes.
Angle bracket attached to front of box with screws.
Angle bracket attached to front of box with screws.
Angle bracket in back
Angle bracket in back
Attach to seat frame with short self-tapping sheet metal screws.
Attach to seat frame with short self-tapping sheet metal screws.
Marking the cut-out for the speakers.  Bottom is still only temporarily attached with screws at this point...  Just in case you cut something incorrectly...
Marking the cut-out for the speakers. Bottom is still only temporarily attached with screws at this point… Just in case you cut something incorrectly…
Cutting with jig saw is the best solution.
Cutting with jig saw is the best solution.
Start with drilling a pilot hole.
Start with drilling a pilot hole.
One down, one to go...  I also drilled a small hole to run the wires thru toward the bottom center.
One down, one to go… I also drilled a small hole to run the wires thru toward the bottom center.
Another test fit.
Another test fit.
Another test fit.  All's good so far.
Another test fit. All's good so far.
Another test fit.  Also check the sound.  All's good so far.
Another test fit. Also check the sound. All's good so far.
Time to glue and screw the bottom plate to the box.
Time to glue and screw the bottom plate to the box.
Now to cut the seat foam.  Mark the cut lines with a sharpie before starting.
Now to cut the seat foam. Mark the cut lines with a sharpie before starting.
An electric knife is great for removing foam.
An electric knife is great for removing foam.
You can always take more off, but it's difficult to add it back.  Take a little at a time to be safe.
You can always take more off, but it's difficult to add it back. Take a little at a time to be safe.
Test fit.  Fits good.  Time to put the seat cover back on.
Test fit. Fits good. Time to put the seat cover back on.
Test fit.  Fits good.  Time to put the seat cover back on.
Test fit. Fits good. Time to put the seat cover back on.
Seat cover back on securely.  All fits well.  Have to round of a corner of the box as to not put too much stress on the vinyl and maybe rip it someday.  Just grind it down a bit.
Seat cover back on securely. All fits well. Have to round of a corner of the box as to not put too much stress on the vinyl and maybe rip it someday. Just grind it down a bit.
I left a little extra foam on the seat to make it a little more cushioned so it looks a little puffy...
I left a little extra foam on the seat to make it a little more cushioned so it looks a little puffy…
Ready to test fit again...
Ready to test fit again…
I like it...
I like it…
Time to cut holes out of carpet on bottom of seat.  Just use a sharp utility knife and follow the circle.
Time to cut holes out of carpet on bottom of seat. Just use a sharp utility knife and follow the circle.
Wire up the speakers and install.  I soldered them for a good connection.
Wire up the speakers and install. I soldered them for a good connection.
Installed.  Add the speaker covers next and add the custom plug on the speaker wires.  (4-pin molex connector)
Installed. Add the speaker covers next and add the custom plug on the speaker wires. (4-pin molex connector)
Wires relocated on amp.  I glued two 1/4" MDF pieces on the bottom of the carpet to screw the amp down.  You can see female side of the molex plug here.
Wires relocated on amp. I glued two 1/4" MDF pieces on the bottom of the carpet to screw the amp down. You can see female side of the molex plug here.
Relocated the RCA input wires also.
Relocated the RCA input wires also.
Seat back and bottom re-assembled.  Ready to final install.
Seat back and bottom re-assembled. Ready to final install.
Installed!
Installed!
Connected and tested... IT WORKS!!!
Connected and tested… IT WORKS!!!
Even with the extra cushioning it still folds up behind my custom made center console.
Even with the extra cushioning it still folds up behind my custom made center console.
Seat back in regular position.
Seat back in regular position.
Stock look.  Custom sound!!  Storage room back!
Stock look. Custom sound!! Storage room back!
Before   ---    After
Before — After


1 Comment

  1. avatar gnfoster said:

    January 26, 2011 @ 2:11 pm

    Well, I did sacrifice a bit of comfort. 99% of the time we are riding our Black Lab around in the back seat. He doesn’t complain. He doesn’t complain when he has to eat dog food either, but…

    I have ridden on it a couple times and it is less comfortable than it was. I left approximately 1 to 1 1/2″ of foam, but the bottom seat top actually sets about 1″ higher than stock. It’s hard to tell in the photos, but it does. The foam is quite dense. The comfort came not only from thicker foam, but also from the thin bracing on the seat-bottom.

    It’s not too bad, but it is nothing like it was. When I sit in the seat, I actually sit higher because it doesn’t have as much give as originally. It can get rough when you’re on a bumpy road. It would likely be very uncomfortable when off-roading.

    I made this box as deep as possible for sound and still have the seat-bottom carpet cover the box. It’s a very tight fit. Sure makes for a heavy seat to take in and out also…

    Raising your seat may allow you to leave extra foam, BUT without making the box thinner it may not fit into the seat cover. To keep it as original as possible I made it fit into the seat cover, therefore, it could still only be so deep. Even it I took ALL of the foam, it could still be only so deep. Raising the seat would not help me because of those limitations still. If I didn’t care if the seat-bottom carpet was left on, I could have dropped the box down a bit and left more foam.

    You definitely need more foam than I left if you want comfort. The kids may even be willing to sacrifice comfort for the sound, but don’t take them off-roading with this mod.

    Would love to see pics if you give it a shot!